Plastic system and method of porous bioimplant having a unified connector

ABSTRACT

The present invention relates to a system and a method of manufacturing a porous bio-implant having a connecting member integrally formed therewith, and more particularly, to a system and a method of manufacturing a porous bio-implant in which a connecting member is integrally formed by sintering a metal powder by a high voltage instant discharge in the state that the connecting member is inserted in a pyrex tube and then the metal powder is put in the pyrex tube. A system of manufacturing a porous bio-implant having a connecting member formed integrally therewith includes a power supply supplying a low voltage; a voltage booster for boosting the low voltage supplied from the power supply to a high voltage; a condenser charging the high voltage boosted by the voltage booster through a switch; a vacuum switch for instantaneously discharging the high voltage charged in the condenser; and a bio-implant manufacturing apparatus for manufacturing a bio-implant by the high voltage discharged instantaneously from the vacuum switch.

This is a nationalization of PCT/KR01/01864 filed Nov. 3, 2001 andpublished in English.

TECHNICAL FIELD

The present invention relates to a system and a method of manufacturinga porous bio-implant having a connecting member integrally formedtherewith, and more particularly, to a system and a method ofmanufacturing a porous bio-implant in which a connecting member isintegrally formed by sintering a metal powder by a high voltage instantdischarge in the state that the connecting member is inserted into apyrex tube and then the metal powder is put in the pyrex tube.

BACKGROUND ART

A conventional non-porous implant of a screw type and a conventionalporous implant manufactured by a high temperature sintering aredescribed with reference to FIGS. 1 and 2.

FIG. 1 is a perspective view illustrating a porous screw-type implantmanufactured by a mechanical processing according to a conventional art.FIG. 2 is a front view illustrating an implant manufactured by a hightemperature sintering according to a conventional art.

A screw-type implant 10 is manufactured by a mechanical processing usinga milling machine 20. Thus, a processing is very difficult, and alengthy processing time is required. Also, due to a formation of anoxide film by a secondary processing, a manufacturing cost is high. Inaddition, a bonding power is poor due to a small contacting area to abone or a fibrous tissue when implanted into body tissue, and thereforethe implant 10 can be easily removed from the body tissue. In the casethat a large-sized implant is implanted into body tissue so as toovercome this problem, a treatment time period becomes lengthy, and theimplant can locally be implanted into only body tissue having arelatively high bone density and having a large size.

In effort to overcome these problems, a method of manufacturing a porousimplant by sintering metal powders at a high temperature has beenintroduced.

As shown in FIG. 2, metal powders 30 are put in a mold 40 and sinteredat a high temperature during a long time period. Or, as shown in FIG.2B, after putting the metal powers in the mold 40, a bar 50 is insertedto pass through a central portion of the metal powders 30, and the metalpowders 30 are sintered at a high temperature during a long time period.

However, the method of FIG. 2 has a problem in that a metal inherentnature variation, a low durability, a surface variation, a lengthysintering, and a high production cost.

Accordingly, there is a need for a technique of manufacturing a newimplant in which a production cost is low, a contacting area between theimplant and the bone is improved, a bonding power between the implantand the bone, a durability is high, a life span is lengthy, a treatmentperiod is short, and a compression strength can be adjusted by adjustinga size of the implant.

DISCLOSURE OF INVENTION

To overcome the problems described above, preferred embodiments of thepresent invention provide a system and a method of manufacturing aporous bio-implant having a connecting member formed integrallytherewith in which does not require subsequent processes because a metalpower in a pyrex tube is sintered by a high temperature instantdischarge and so attached to the connecting member.

It is another object of the present invention to provide a system and amethod of manufacturing a porous bio-implant having a connecting memberformed integrally therewith which can adjust a compression strengthaccording to a location of respective teeth by adjusting a size of theconnecting member.

The system of manufacturing a porous bio-implant having a connectingmember formed integrally therewith includes a power supply for supplyinga low voltage; a voltage booster for boosting the low voltage suppliedfrom the power supply to a high voltage; a condenser charging the highvoltage boosted by the voltage booster through a switch; a vacuum switchfor instantaneously discharging the high voltage charged in thecondenser; and a bio-implant manufacturing apparatus for manufacturing abio-implant by the high voltage discharged instantaneously from thevacuum switch.

The bio-implant manufacturing apparatus includes a hollow pyrex tube;the connecting member inserted into the pyrex tube; a metal powderinserted in an inner space of the pyrex tube under the connectingmember; an upper electrode inserted into an upper opening of the pyrextube and rested on an upper surface of the connecting member; and alower electrode inserted into a lower opening of the pyrex tube topressurize the metal powder.

The connecting member includes a connecting member main; a headerportion integrally formed on an upper central portion of the connectingmember main, and a screw hole formed in a predetermined depth under theheader portion.

The lower electrode has a concave groove formed in a predetermienddepth. The bio-implant manufactured by the bio-implant manufacturingapparatus is integrally formed with the connecting member by sinteringthe metal powder by combination of a pinch pressure and a heat energy,and has a porous layer on an outer surface thereof.

A surface roughness of the bio-implant manufactured by the bio-implantmanufacturing apparatus is determined by adjusting a size of the metalpowder. A compression strength of the bio-implant manufactured by thebio-implant manufacturing apparatus is determined by adjusting a size ofthe connecting member.

A method of manufacturing a porous bio-implant having a connectingmember formed integrally therewith includes the steps of: inserting theconnecting member into a pyrex tube through an upper opening of thepyrex tube; inserting a metal powder into the pyrex tube through a loweropening of the pyrex tube; inserting an upper electrode through theupper opening of the pyrex tube and resting the upper electrode on theupper surface of the connecting member, and inserting a lower electrodethrough the lower opening of the pyrex tube; supplying a low voltagefrom a power supply connected to the upper and lower electrodes;boosting the low voltage to a high voltage by a voltage booster;charging the high voltage boosted by the voltage booster in thecondenser through a switch; discharging the high voltage charged in thecondenser instantaneously through the vacuum switch; and sintering themetal powder in the pyrex tube, thereby forming a porous bio-implantintegrally with the connecting member.

BRIEF DESCRIPTION OF DRAWINGS

For a more complete under supporting of the present invention and theadvantages thereof, reference is now made to the following descriptionstaken in conjunction with the accompanying drawings, in which likereference numerals denote like parts, and in which:

FIG. 1 is a perspective view illustrating a screw-type implantmanufactured by a mechanical processing according to a conventional art;

FIG. 2 is a front view a porous implant manufactured by a hightemperature sintering according to a conventional art;

FIG. 3 is a circuit diagram a porous bio-implant manufacturing systemaccording to one embodiment of the present invention;

FIG. 4 shows the porous bio-implant manufacturing apparatus according tothe present invention

FIG. 5 is a block diagram illustrating the porous bio-implantmanufacturing system according to one embodiment of the presentinvention;

FIG. 6 is a cross-sectional view illustrating various pyrex tubesaccording to one embodiment of the present invention;

FIG. 7 is a front view illustrating a porous bio-implant manufacturedaccording to one embodiment of the present invention;

FIG. 8 is a cross-sectional view illustrating the porous bio-implantmanufactured according to one embodiment of the present invention;

FIG. 9 is a front view illustrating a porous layer of the porousbio-implant manufactured to one embodiment of the present invention;

FIG. 10 is a front view illustrating pores of the porous layer of theporous bio-implant manufactured to one embodiment of the presentinvention;

FIG. 11 is a flow chart illustrating a process of manufacturing a porousbio-implant according to one embodiment of the present invention;

FIG. 12 is a circuit diagram illustrating a porous bio-implantmanufacturing system according to another embodiment of the presentinvention;

FIG. 13 is a cross-sectional view illustrating a porous bio-implantmanufactured according to another embodiment of the present invention;and

FIG. 14 is a flow chart illustrating a process of manufacturing a porousbio-implant according to another embodiment of the present invention.

BEST MODE FOR CARRYING OUT THE INVENTION

Reference will now be made in detail to preferred embodiments of thepresent invention, example of which is illustrated in the accompanyingdrawings. Like reference numerals denote like parts.

FIG. 3 is a circuit diagram a porous bio-implant manufacturing systemaccording to one embodiment of the present invention. FIG. 4 shows theporous bio-implant manufacturing apparatus according to the presentinvention. FIG. 5 is a block diagram illustrating the porous bio-implantmanufacturing system according to one embodiment of the presentinvention. FIG. 6 is a cross-sectional view illustrating various pyrextubes according to one embodiment of the present invention. FIG. 7 is afront view illustrating a porous bio-implant manufactured according toone embodiment of the present invention. FIG. 8 is a cross-sectionalview illustrating the porous bio-implant manufactured according to oneembodiment of the present invention. FIG. 9 is a front view illustratinga porous layer of the porous bio-implant manufactured to one embodimentof the present invention. FIG. 10 is a front view illustrating pores ofthe porous layer of the porous bio-implant manufactured to oneembodiment of the present invention.

The porous bio-implant manufacturing system includes a power supply 60,a voltage booster 70, a first switch 80, a condenser 90, a vacuum switch100, and a porous bio-implant manufacturing apparatus 110.

The porous bio-implant manufacturing apparatus 110 includes a pyrex tube112, 112 a or 112 b to which a metal powder 111, 111 a or 111 b, upperand lower electrodes 113, 113 a or 113 b which is inserted into andattached to the pyrex tube 112, 112 a or 112 b, upper and lowerelectrode holders 114, upper and lower suspension members 115, and amain support 116.

The pyrex tube 112, 112 a or 112 b are hollow, and the metal powder 111,111 a or 111 b is put on the middle of the pyrex tube 112, 112 a or 112b. The pyrex tube 112, 112 a or 112 b is preferably made of quartz, andcan have various shapes.

The upper and lower electrodes 113, 113 a or 113 b are inserted into andattached to both upper and lower openings of the pyrex tube 112, 112 aor 112 b. The upper and lower electrode holders 114 firmly hold theupper and lower electrodes 113, 113 a or 113 b. The upper and lowerelectrodes 113, 113 a or 113 b are preferably made of copper or brass.

The upper and lower suspension members 115 connect the upper and lowerelectrode holders 114 to the main support 116, respectively.

Operation of the porous bio-implant manufacturing system is describedbelow.

A low voltage of 100 volts or 200 volts is supplied from the powersupply 60. The voltage booster 70 boosts the low voltage to a highvoltage of 1000 volts to 5000 volts and preferably to a high voltage of2500 volts. The high voltage passes through the first switch 80 andcharges the condenser 90. The high voltage charged in the condenser 90are discharged instantaneously through the vacuum switch 100 to sinterthe metal powder 111, 111 a or 111 b in the pyrex tube 112, 112 a or 112b, thereby forming a porous bio-implant according to one embodiment ofthe present invention.

The porous bio-implant has an inner solid tissue and an outer porouslayer. The inner solid tissue increases a durability of the bio-implant.The outer porous layer b allows for bone growth or fibrous tissue growthand malleable to allow it to conform to various shapes, therebyproviding a strong, solid support when fixed to the bone and increasinga life span of the bio-implant. A pore size of the porous layer b ispreferably in a range between 100 μm and 200 μm.

In greater detail, the metal powder 111, 111 a or 111 b in the pyrextube 112, 112 a or 112 b is sintered by an electro discharge sintering(EDS) technique to forming pores on an outer surface of the porousbio-implant and form a solid core on an inner portion of the porousbio-implant. This mechanism is performed by combining a pinch pressurerequired to transform and squeeze the metal powder 111, 111 a or 111 band a heat energy required to weld the metal powder 111, 111 a or 111 b.

A relationship between the heat energy and the solid core size isanalyzed using experimental data as follows: a size of the solid core is2.24 μm when a heat energy is 977 [J], and a size of the solid core is2.47 μm when a heat energy is 1,340 [J]. It is understood that a size ofthe solid core is proportion to a heat energy.

A surface roughness of the porous bio-implant depends on a size of themetal powder 111, 111 a or 111 b. The solid core, a processing size, aprocessing rate, and a durability can be controlled by varying acapacity of the condenser 90, that is, varying an amount of an electricenergy charged in the condenser 90.

FIG. 11 is a flow chart illustrating a process of manufacturing a porousbio-implant according to one embodiment of the present invention.

First, the metal powder 111, 111 a or 111 b is put in the middle of thepyrex tube 112, 112 a or 112 b (step S100). The upper and lowerelectrodes 113, 113 a or 113 b are inserted into and attached to bothupper and lower openings of the pyrex tube 112, 112 a or 112 b (stepS200).

A low voltage of 100 volts or 200 volts is supplied from the powersupply 60 (step S300). The voltage booster 70 boosts the low voltage toa high voltage of 1000 volts to 5000 volts and preferably to a highvoltage of 2500 volts (step S400). The high voltage passes through thefirst switch 80 and charges the condenser 90 (step S500).

The high voltage charged in the condenser 90 are dischargedinstantaneously through the vacuum switch 100 (step S600) to sinter themetal powder 111, 111 a or 111 b in the pyrex tube 112, 112 a or 112 b,thereby forming a porous bio-implant (step S700).

FIG. 12 is a circuit diagram illustrating a porous bio-implantmanufacturing system according to another embodiment of the presentinvention. FIG. 13 is a cross-sectional view illustrating a porousbio-implant manufactured according to another embodiment of the presentinvention.

The porous bio-implant manufacturing system according to anotherembodiment of the present invention includes a power supply 120, avoltage booster 130, a first switch 140, a condenser 150, a vacuumswitch 160, and a porous bio-implant manufacturing apparatus 170.

A low voltage of 100 volts or 200 volts is supplied from the powersupply 120. The voltage booster 130 boosts the low voltage to a highvoltage of 1000 volts to 5000 volts and preferably to a high voltage of2500 volts. The high voltage passes through the first switch 140 andcharges the condenser 150. The high voltage charged in the condenser 150are discharged instantaneously through the vacuum switch 160.

The porous bio-implant manufacturing unit 170 includes a pyrex tube 172,upper and lower electrodes 173 a and 173 b, and a connecting member 174.

The pyrex tube 172 is hollow and is preferably made of quartz. The pyrextube 172 can have various shapes. The upper and lower electrodes 173 aand 173 b are made of copper or brass.

The connecting member 174 includes a connecting member main 174 a, aheader portion 174 b and a screw hole 174 c. The connecting member main174 a preferably has a cross-section of a cross shape. The headerportion 174 b is formed on an upper central portion of the connectingmember main 174 a and preferably has a hexagon. The screw hole 174 c isformed to a predetermined depth under the header portion 174 b.Preferably, a distance between opposite sides of the header portion 174b is 2.7 mm, and a diameter of the screw hole 174 c is 2.0 mm. Theconnecting member 174 can have various shapes.

The connecting member 174 is inserted into the pyrex tube 172 through anupper opening of the pyrex tube 172. A metal powder 171 is inserted intothe middle of the pyrex tube 172 through a lower opening of the pyrextube 172.

The upper electrode 173 a is inserted through the upper opening of thepyrex tube 172 and rested on the upper surface of the connecting member174. The lower electrode 173 b having a concave surface is insertedthrough the lower opening of the pyrex tube 172. The upper and lowerelectrodes 173 a and 173 b are preferably made of Cu, brass, Gr, Ag—W,Cu—W, or Pt. The upper surface of the lower electrode 173 b can havevarious shapes other than a concave shape.

Operation of the porous bio-implant manufacturing system is describedbelow.

A low voltage of 100 volts or 200 volts is supplied from the powersupply 130. The voltage booster 140 boosts the low voltage to a highvoltage of 1000 volts to 5000 volts and preferably to a high voltage of2500 volts. The high voltage passes through the first switch 140 andcharges the condenser 150.

The high voltage charged in the condenser 150 are dischargedinstantaneously through the vacuum switch 160 to sinter the metal powder171 in the pyrex tube 172, thereby forming a porous bio-implantintegrally with the connecting member 174.

The porous bio-implant has an inner solid tissue and an outer porouslayer. The inner solid tissue increases a durability of the bio-implant.The outer porous layer allows for bone growth or fibrous tissue growthand malleable to allow it to conform to various shapes, therebyproviding a strong, solid support when fixed to the bone and increasinga life span of the bio-implant. A pore size of the porous layer ispreferably in a range between 100 μm and 200 μm. A surface roughness ofthe porous bio-implant depends on a size of the metal powder 171. Acompression strength of the porous bio-implant is determined by a sizeof the connecting member 174.

The porous bio-implant having the connecting member 174 formedintegrally therewith is manufactured by combining a pinch pressurerequired to transform and squeeze the metal powder 171 and a heat energyrequired to weld the metal powder 171.

FIG. 14 is a flow chart illustrating a process of manufacturing theporous bio-implant according to another embodiment of the presentinvention.

The connecting member 174 is inserted into the pyrex tube 172 throughthe upper opening of the pyrex tube 172 (step S100 a). A metal powder171 is inserted into the middle of the pyrex tube 172 through the loweropening of the pyrex tube 172 (step S200 a).

The upper electrode 173 a is inserted through the upper opening of thepyrex tube 172 and rested on the upper surface of the connecting member174. The lower electrode 173 b having a concave surface is insertedthrough the lower opening of the pyrex tube 172 (step S300 a).

A low voltage of 100 volts or 200 volts is supplied from the powersupply 120 (step S400 a). The voltage booster 130 boosts the low voltageto a high voltage of 1000 volts to 5000 volts and preferably to a highvoltage of 2500 volts (step S500 a). The high voltage is charged thecondenser 150 through the first switch 140 (step S600 a).

The high voltage charged in the condenser 150 is dischargedinstantaneously through the vacuum switch 160 (step S700 a) to sinterthe metal powder 171 in the pyrex tube 172, thereby forming a porousbio-implant integrally with the connecting member 174 (step S800 a).

INDUSTRIAL APPLICABILITY

As described herein before, the porous bio-implant has the followingadvantages. Since the porous bio-implant is integrally formed with theconnecting member, a subsequent manufacturing process is not required,leading a simplified manufacturing process, a high throughput, and ahigh processing precision. A compression strength of the porousbio-implant can be adjusted by adjusting a size of the connectingmember.

While the invention has been particularly shown and described withreference to preferred embodiments thereof, it will be understood bythose skilled in the art that the foregoing and other changes in formand details may be made therein without departing from the spirit andscope of the invention.

1. A method of manufacturing a porous-bio-implant having a connectingmember formed integrally therewith, comprising the steps of: inserting aconnecting member into an upper opening of a pyrex tube; inserting ametal powder into the pyrex tube through a lower opening of the pyrextube; inserting an upper electrode through the upper opening of thepyrex tube and resting the upper electrode on an upper surface of theconnecting member, and inserting a lower electrode through the loweropening of the pyrex tube; supplying a low voltage from a power supplythat is connected to the upper and lower electrodes; boosting the lowvoltage to a high voltage by subjecting the low voltage to a voltagebooster; charging the high voltage boosted by the voltage booster in acondenser through a first switch; and discharging the high voltagecharged in the condenser instantaneously through a vacuum switch tosinter the metal powder in the pyrex tube, thereby forming abio-implant, having a porous outer layer and a inner solid tissue,integrally with the connecting member.
 2. The method of claim 1, whereininserting a connecting member further comprises inserting a connectingmember, which includes a connecting member main, a header portionintegrally formed on an upper central portion of the connecting membermain and a screw aperture, into an upper opening of a pyrex tube.
 3. Themethod of claim 1, wherein supplying a low voltage further comprisessupplying a voltage in the range of about 100 volts to about 200 voltsfrom a power supply that is connected to the upper and lower electrodes.4. The method of claim 1, wherein boosting the low voltage to a highvoltage further comprises boosting the low voltage to a high voltage inthe range of about 1000 volts to about 5000 volts.
 5. The method ofclaim 1, wherein boosting the low voltage to a high voltage furthercomprises boosting the low voltage to a high voltage of about 2500volts.
 6. The method of claim 1, further comprising pressurizing themetal powder in the pyrex tube by applying pinch pressure between theupper and lower electrodes.
 7. The method of claim 1, further comprisingchoosing the metal powder based on a size to determine a surfaceroughness of the resulting porous bio-implant.
 8. The method of claim 1,further comprising choosing the connecting member based on a size todetermine a compression strength of the resulting bio-implant.